How to fix Clark Forklift Brakes

October 22, 2020

Clark forklift brake systems are fairly straight forward to work on. Some have wet brakes, others utilize traditional brake shoe brake set ups.

Replacing Brakes Overview

Brakes are vital to an equipment’s efficiency and usability. It’s important to replace brakes when they are worn down to maintain the safety of the operator and the wellbeing of the equipment. Luckily, replacing forklift brakes is not an overwhelming task and can be performed with just a little mechanical skill.

This tutorial will outline how to fix Clark forklift brakes with brake shoes.

To start, remove hardware

Next, remove studs

Next, cap the brake line

Next, remove wheel cylinder

Next, spray down and clean assembly with brake parts cleaner

Next, re-install wheel cylinder

Next, use Loctite on studs

Most hardware can be re-used.

Then, Re-install brake hardware

Install new brake shoes

Press-in new seals

Re-install new wheel bearing

Re-install brake drum

Finally, Re-install cushion tire and wheel

Full video: Click Here

Intella Parts Company proudly sells a broad range of forklift parts for many forklift brands, including Clark. In addition, Intella offers industry renowned customer service! Call now at 616-796-6638!

Interested in more help to guides? Intella has a YouTube page!

Post by Intella Parts Company, LLC

How to Replace a Toyota Forklift Seat

October 22, 2020

A worn out seat is no fun, especially if you’re expected to sit in it for multiple continuous hours. Luckily, Intella offers a selection of replacement seats, and this blog will outline how to replace a Toyota forklift seat.

Toyota forklifts with model numbers that begin with 6 or 7 (like 6FGCU25 or 7FGCU25) use unique seats custom designed for Toyota. Intella offers aftermarket replacements for these seats. There are no replacement cushions available for these seats because of the design of the seat.

How to Replace Your Forklift Seat Yourself

It’s super easy to replace a Toyota forklift seat yourself, all you need are a socket set and a little mechanical ability.

Swing out the LPG tank. There’s a latch on the back near the tank which will allow you to swing it out.

Slide the old seat all the way forward

Find the hood release and open the hood

Remove 4 bolts from the bottom of the forklift seat deck.

Remove the old seat

Fit the new seat in place. Our seat will fit exactly, no drilling should be required.

Fasten in place with new bolts

For full video: Click here

Need a toyota forklift seat or want to see our full lineup of our forklift seats? Intella Parts Company can help!

Have a question on how to replace a Toyota forklift seat? Call us at 616-798-6638.

Post by Intella Parts Company, LLC

How to fix an Aisan Fuel Regulator

October 22, 2020

“How to fix an Aisan fuel regulator” is a common question for equipment owners, so we, at Intella, decided to create an outline on how to fix one. Given how important the fuel regulator is to your equipment, it’s important to keep them well intact. This blog will give step by step directions on how to fix your regulator.

Brief Aisan Fuel Regulator Introduction

Aisan fuel systems are used in a variety of different forklifts including Toyota, Hyster, and Yale. Aisan is partly owned by Toyota so you see mainly see these regulators in Toyota forklifts.

Rebuild or Replace the Entire Unit

Rebuilding an Aisan regulator is a bit more difficult than the traditional and popular Impco model J. Depending on your skill level, you might want to simply replace the entire unit.

How to Rebuild the Aisan Regulator

Remove solenoid from unit

Remove back studs with socket

Remove seals and pad

Remove screws

Remove parts from new Aisan repair kit

Re-install valve parts

Re-install back cover

Install diaphragm

Install o-ring and spring

Re-install pad and oring

Re-install sintered metal filter

Re-install solenoid

For full length YouTube video: Click Here

Buying an Aisan Fuel Regulator

Looking to purchase an Aisan fuel regulator? Buy one here! If you have any other questions, please call us at 616-796-6638 and speak to one of our industry renowned customer support specialists.

Post by Intella Parts Company, LLC

How to Fix Forklift Steer Axle

October 22, 2020

This blog will give a picture based guide how to fix your forklift steer axle. Steer axles take a beating on forklifts. There are a number of wear components which wear out and get damaged. In this tutorial you’ll see how to replace some of the most common wear items.

Intella Parts also offers complete remanufactured axles as well. This might be the best option if you have extreme wear on the cast portion of the steer axle.

Fix Forklift Steer Axle

Install new needle bearings

Check fit and install new king pin

Re-install knuckle

Install shims and thrust bearings

Check operation of knuckle

Install bearings on opposite side

Tap out bearing for cylinder mounting

Try fit on dog bone link

Install pins

Install pins and dog bone on opposite side of knuckle

Install grease fittings

Apply grease to each grease fitting

For full video: Click here

If you are looking to purchase a forklift steer axle, Intella Parts offers a wide selection of different options in addition to our massive selection of parts.

Unsure of which one you need? Give us a call at 616-796-6638 to speak with one of our customer support specialists and experience our industry renowned customer service!

Post by Intella Parts Company, LLC

Tagged fix forklift steer axle, forklift steer axle

How to Replace a Forklift Master Cylinder

October 22, 2020

How to replace a forklift master cylinder: Forklift brake systems typically use a master cylinder often mounted beneath the operator floor panel. The master cylinder is vital for your equipment’s brakes. The master cylinder works as a hydraulic pump that puts in brake fluid to convert brake pedal pressure into hydraulic pressure.

Instructions:

To start, remove the floor panels, find the master cylinder and go to work. This tutorial will show the replacement of a master cylinder on a Hyster 5000 pound forklift with a corresponding full video.

To start, remove your old master cylinder unit

Remove the old master cylinder unit

Next, remove the lines

Then, install the new master cylinder

Re-install pin and retaining clip

Fill reservoir with brake fluid

Test system and make adjustments

Bleed excess air from system

To watch the full video: click here

Parts used in this tutorial:

master cylinder

brake fluid

Need Toyota brake parts? We got them! If you have any questions on how to replace a forklift master cylinder, give Intella a call at 616-796-6638 and experience our industry renowned customer support. Feel free to comment on this blog post, as well.

Intella offers a wide selection of parts, including forklift parts. Visit our website to explore our wide catalog of parts!

Post by Intella Parts Company, LLC

Tagged forklift master cylinder, replace a forklift master cylinder

Propane Gas Smell from Forklift

October 22, 2020

One of the most common forklift complaints from forklift operators is a noticeable propane gas smell from your forklift — this can likely be attributed to the need to replace o-rings. Frequent forklift operators will call service companies complaining that their forklift has a leak. Often, the problem is not with the forklift but rather with the propane tank.

This tutorial will show how to replace two o-rings on the propane tank and eliminate one of the most common complaints from forklift operators and get rid of that pestering gas smell from your forklift.

Remove the existing o-rings

There’s a square style o-ring and a round oring

Here’s a cross section view of how the o-rings are placed in the connector

Replace with new o-rings

For full video: click here

Need to purchase o-rings? Navigate to our website and search ‘o-rings’ in the search field! Intella Parts sells all of the parts for your equipment needs. Navigate to our by-type page to filter by part types to fulfill all of your part needs.

Need help on figuring out which o-rings you need for your forklift model? Call us at 616-796-6638 to speak with one of our customer support specialists that can help with part lookups!

Post by Intella Parts Company, LLC

Tagged gas forklift, gas smell from forklift, o-rings forklift, propane forklift, propane gas smell from forklift, replace o-rings forklift

How to Rebuild Impco Model J Regulator

October 22, 2020

The Impco model J regulator is the most popular LPG regulator on the market today, yet it is no longer used in current models of forklifts due to emissions regulations.

Impco model J regulators are found in a most brands of forklifts along with other LPG powered equipment like Tennant or American Lincoln scrubber units and even Zamboni ice resurfacers.

Replace or Rebuild?

Inside the model J are diaphragms made of hydrin or silicone. These wear out or tear and need to be replaced. The first decision you’ll have to make is if you want to replace the entire model J unit or rebuild the unit with a repair kit. Either decision is fine, it just depends on how you value your time.

You will see in the tutorial below that rebuilding a model J is pretty simple. There are times when a model J might be mounted inside a forklift where it’s easier to rebuild the unit instead replacing the entire unit. It just depends on the location of the model J.

How the Part Numbers are Designated

One more note. Model J is Impco’s designation for an entire series of LPG regulators. There’s a method to how the Impco part numbers work:

Model JB = Model J with Blue spring. Blue spring units have Neg. 0.37 kPa pressure. This is the standard and most common model J.

Model JO = Model J with Orange spring. Orange spring units have Neg. 0.12 kPa pressure. This is the lease common model J. You should stick with the model J that is already installed in your forklift.

After the letters JB or JO, you sometimes see a -2 like this: JB-2. The -2 indicates the diaphragms are manufactured from silicone. No letter means the diaphragms are made from black hydrin rubber. Silicone (yellow) diaphragm material is the optional upgrade material that provides excellent flexibility in cold weather climates and is more resistant to chemical contamination. They can be used interchangeably, if you want to upgrade, go with the silicone material.

Rebuilding the Model J

Remove screws from front of unit. The screws are typically 9-32 x 7/8″ Torx style

Remove diaphragm from inside cover

Remove lever. Screw is also a Torx screw

Remove the screws from the back of the model J unit.

Take the halves apart and remove the old diaphragm.

Re-install the diaphragms and metal seat.

Re-install cover and screws

Re-install cover and screws

For full video: click here

Post by Intella Parts Company, LLC

Tagged impco, impco model j, model j regulator

How To Fix Forklift Brakes

October 20, 2020

Overview

Forklift brakes are fairly straight forward to replace, especially for someone with automotive experience. Forklift brake systems are traditional brake drum/brake shoe set ups, very similar to what an automobile would use in the 1960s and 1970s. Most forklift manufacturers recommend a complete brake inspection every 2000 operating hours. Brake system (shoes, drum, etc) are wear items are there’s no typical lifespan. If you use your brakes a lot, you’ll need to replace brake shoes more frequently. It probably goes without saying but brakes are only on the front axle on forklifts. The rear axle does not have brakes.

This tutorial walks you through a typical forklift brake job. The example forklift was a Toyota 6FGCU18 but the same system will be found on other brands of forklifts as well such as Hyster, Yale, CAT, Mitsubishi and others. Wet disk brakes are a thing in the forklift industry but somewhat rare. Clark, Doosan, and CAT used wet disk brakes throughout the years. If you have a wet disk brake set up, the below tutorial will NOT apply for your forklift.